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PowerTrain Library 1.0
Christian SchweigerInstitute of Robotics and Mechatronics
Deutsches Zentrum für Luft- und Raumfahrt e. V.Oberpfaffenhofen, Germany
Modelica Automotive WorkshopNovember 19, 2002
Ford Research LaboratoryDearborn, MI, USA
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Outline
Library overview
Components
Applied concepts
Usage
Implementation
Case study
Online demonstration
Conclusions and outlook
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The DLR PowerTrain Library
Commercial library of DLR with primarily 1D rotational mechanicalcomponents. Suitable for
Examination of gear shift dynamics
Hardware-in-the-loop simulation of automatic gearboxes
Concept studies of drive lines (e.g. fuel consumption reduction)
...
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History
1996: Project with BMW for HIL simulation of automatic gearboxes(using the Dymola language)
2000: Version 0.95 of PowerTrain library using the Modelica language(sold to BMW and other automotive companies)
2001: Start to considerably enhance the PowerTrain library
2002: Release of PowerTrain 1.0
Direct Contributors
Ingrid Bausch-Gall, Bausch-Gall GmbH, Germany
Mike Dempsey, Claytex Services Ltd, UK
Martin Otter, DLR, Germany
Clemens Schlegel, Schlegel Simulation GmbH, Germany
Christian Schweiger, DLR, Germany
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PowerTrain Library Features
45 user-callable components
Signal bus concept
Variant selection
Robust friction modeling
Torque dependent losses (e.g. mesh efficiency)
Animation of transmission components
10 introductory and sophisticated examples
Universal control units
Online tutorial
4-speed
6-speed
5-speed
gearbox
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Library Structure
DriveLine
Examples Interfaces Main Gears
Clutches ControlUnits Auxiliaries Visualizers
PowerTrain
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Model DriveLine
Library top-level view:generic drive train
Different configurationsselectable for every component(e.g. 3 gearbox variants)
User can add own variants
Template for building own models
Used as a basis for sophisticateddemo examples
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Sublibrary Main
Collection of models for generic power train Main
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Sublibrary Main
Different configurationsselectable
Realized by replaceable-redeclare-concept
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Sublibrary Gears
Content
Gear components
Standard gears
Complete wheelsets
Color coding
Red: losses due to meshefficiency and bearingfriction
Brown: built-in animation
Gears
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Other Sublibraries
Clutches AuxiliariesControlUnits
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Modelica connector containing allsignal- or other sub-connectors
used in the drive line
Concept of Signal Bus
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Efficiency Modeling
Locking due to mesh friction Usual approach
2001 =τ 1902 =τ
1=i 9,01 =mfη 1
AAωτ
mfη̂
Flange 1 driving:Flange 2 driving:
211 τητ <mf
112 τητ <mf Flange 1 drivingFlange 2 driving
Chattering possible
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Efficiency Modeling
Efficiency is free variable while Our approachstuck mode is active
Modelica friction implementationextended for torque dependent losses
Allows robust efficiency modeling
LossyGear
LossyPlanetary
LossyRavigneaux
...
1
AAωτ
mfη̂
Flange 1 drivingFlange 2 driving
Stuck mode
i_0=-2
LossyPlanetary
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Efficiency Modeling
Takes stuck / rolling behaviour into account
Very much better than usual approach
Example
Inertia1
J=1
Inertia2
J=1.5
torque1
tau
torque2
tau
DriveSine
freqHz={1}
load
duration={2}i_0=-2
gear
Fixed1=0
0 0.25 0.5-0.05
0
0.05Inertia1.w Inertia2.w
0 0.25 0.5-2
0
2gear.mode
gear.mode1 forward rolling0 stuck
-1 backward rolling
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Efficiency Modeling
Torque loss
τ∆
Aτ
),( AA τωττ ∆=∆
)0( >∆ Aωτ
)0( =∆ Aωτ
)0( <∆ Aωτ
τ∆
Aω
Aτ
Aτ
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Animation
Built-in animation for gears, clutches, shafts
Easy parametrization
Possibility to turn off
parameter Boolean animation=false;
Animation equations removed from code(necessary for e.g. real-time simulation)
0 1 2 3 4 65
parameter Real position=4;
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Fully parametrizable, independent from gear type or speed number
Transmission: shift schedule, lock-up clutch control
Engine: governor, fuel map, over-run fuel cut-off control
Example
1
2
n
BasicStrategy
Universal Control Units
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Purposes
Introduction to library
Hints for development of own models
Starting point for own models
B2
B1
Load
J=10
engine1
J=1
torque
tau
engine2
J=0.01
Const...
k={1}
z=20,40,100
planetary1
z=20,40,100
planetary2
C1
C2
lepelletier
?Lepellet...phi
pos itionramp
duration={2}
combiTableTime
speedSe...w
speedSe...w
combiTable1Ds
load
J=10
motor
J=0.1
torque
tau
speedSe...w
controller
PID
Ti=10000
-
feedback
clutchCo...
desiredVelocity
duration={2} wheelset
?Extend...
speedSe...w
basicStr...
...1 2 nspeed
throttle
clock
startTime={0}dummy
k={1}
load
J=10
motor
J=0.1
torque
tau
speedSe...w
controllercontroller
PID
Ti=10000
-
feedback
clutchCo...
desiredVelocitydesiredVelocity
duration={2} wheelset
?Lepellet...
speedSe...w
basicStr...
...1 2 nspeed
throttle
clockclock
startTime={0}dummydummy
k={1}
gearbox
driver
Driver
fullEngineaxle car
bus
PowerTrain.Examples
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ZF 6 HP 26 A B C D
E
Ravigneauxwheelset
Lepelletier type
Example: 6-speed automatic gearbox
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Modelica Object Diagram
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Complexity:- 1304 variables (with animation)
632 variables (without animation)- 15 continuous states
Embedding
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45 New Components for the Modelica Standard Library
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Conclusions and Outlook
Powerful library for different power train modeling tasks
Examination of gear shift dynamics
Hardware-in-the-loop simulation
Drive line studies
Well-designed structuring
Planned for future:
3D Coupling with vehicle dynamics library
Additional standard wheelsets, drivers, engines, ...
Vendor gearboxes(user does not need to identify gearbox, since complete model data setwill be provided)